706 100 183 (TPX 502-1 GB Version 0.0) 23.10.2003

Pad printing machine

TPX 502

GB ____ Operating instruction

Danger Warning for Machine Operation

Standard Tampon There is no risk of injury for the fingers while using standard tampons (tampon strength ≥ 35 to 40 mm) if used as intended. While using special tampons, tampon assembly, etc. additional protective measures must be carried out if required; i.e. two-hand switch, light barrier, loading and unload-ing equipment. Printing matter intake Printing Matter According to the kind / shape of the printing matter / printing matter intake, the risk of injury (jamming risk) between the printing matter / printing matter intake and the ex-tending sword of the tampon cleaning changes. Additional protective measures must be carried out if required; i.e. two-hand switch, light barrier, loading and unloading equipment.

Before casing sheets are taken off, the machine must be shut off and detached from the electricity network!

Settings, color and thinner adiition, as well as any working in the tampon free space may only be carried out when the machine is at rest.

Hazardous Materials (Colors, Lacquers, Solvents, Leveling Agents, etc.) While handling hazardous materials to be used(colors, detergents, additives), the information of each respective safety data sheets must be paid attention to.

3 23.10.2003 TPX 502-1 GB

Technical data 4

Dimension drawing 5

Commissioning procedure 6

Compressed air connection 6

Pot Cylinder 7

Image position on plate 8

Image pick-up 8

Adjustment of the pad slide paths 9

Filling with ink 10

Speed setting 11

Maintenance instructions 12

Check on conditioning unit 13

Cylinder with end-stop damping 13

Power supply unit 14

Nano-T control unit 15

I/O-Modul 16

Exchanging the control unit Nano-T and the I/O module 17

Initiator locations 18

Incremental rotary transducer fitting 19

Emergency stop 20

Contact allocation X4-X5, CAN-Bus, Foot switch 21

Connection for clean unlubricated air 22

Pad fastener 23

Pneumatic diagram 24

Layout diagram 25

Control components and interface 26

Wiring X4/X5 – I/O-Modul 27

Power suplay 28

Assignment of inputs of NANO-T control unit 29

Assignment of outputs of NANO-T control unit 30

Possible printing faults 31

Index

4 TPX 502-1 GB 23.10.2003

Standard plate sizes: 350 x 180 mm Ink pot: ø 160 450 x 180 mm ø 160 450 x 220 mm ø 195 1. Ink pot: According to configuration 2. Print capacity: Depends on the print image 3. Drive: Pneumatic Noise level: < 70 dB (A) 4. Compressed air connection: Working pressure 5-6 bar 5. Printing pressure: Max. 3000 N (300 kp) at 6 bar 6. Air consumption: 4,0 l / cycle at 6 bar 7. Electrical connection: 85 – 265 V, 47 – 63 Hz 8. Control voltage: 24 V = 9. Machine output impulse for No-volts contact automatic feed: Max. voltage 100 V / Max. rating 100 VA 10. Control system: Process PLC with micro-processor and digital I/O module. In order to

monitor the machine movement, contact-free switching initiators with LED are installed.

11. Programming interface: RS232 12. External interface: CAN-Bus 13. Pad stroke: Infinitely variable, electronically

14. Max. pad vertical stroke: 160 mm 15. Max. pad throat depth: 149 mm 16. Setting: Each working movement can be independently actuated by push

button and mode-selector switch. 17. Single cycle or continuous By push button operation: 18. Cycle counter: Can be changed over to subtracting or performance display 19. Speed setting: Infinitely variable, using flow regulators 20. Weight: Bench model: approx: 195 kg 21. Dimensions: Bench model: Width approx.: 612 mm (according to configuration) Height: 850 mm Depth approx.: 1137 mm Subject to modification without notice.

Technical data

27 27

Hub

max

.

4343

1105

500 388

195

535

300

ca. 1137

850

120 16

013

834

5044

5

2083

0

706 450 009

23.10.03 TATPX 502ERSETZT DURCH

ERSATZ FUER

GEZEICHN.

GEPRUEFT

INDEX

8240 THAYNGEN SWITZERLAND

Technische Aenderungen vorbehaltenWe reserve the right to make any technical changesSous reserve de modifications techniquesReservato el derecho de realizar modificaciones tecnicasCon riserva di mutazioni techniche

265

EmpfohleneDruckhöhe

206

ca. 546

SWITZERLAND

C

6 TPX 502-1 GB 23.10.2003

Commissioning procedure Compressed air connection

Commissioning procedure 1. Mains connection (1) Mains voltage according to data-plate on rear of

machine 2. Foot-switch connection (2) 3. Socket for peripheral devices X4/X5 (3) Allocation see on page 21 4. Programming interface PC RS 232 (9 Pol F) 5. Connection Can Bus (15 Pol F)

Compressed air connection 1. Plug-in nippel G1/4“ Legris, serie 22 matching: Aro 210 Cejn 300 Orion 44510 Parker 50 Rectus 14, 22 Plug-in connection on the rear side of the

pressure regulator for non-oiled, filtered air. 4/3 mm hose.

2. Air pressure regulating valve Requi- red working pressure 5-6 bars 3. Pressure gauge 4. Sight glass filter 5. Condensate drain 6. Sight glass oiler 7. Oil feed regulator screw

7 6

2 1 3 4 5

5 4 3 2 1

close open

Output

Input

7 23.10.2003 TPX 502-1 GB

4

5

7

6

Pot cylinder, optional

1 Rotary switch for pot hold down (6).

Important: The pot hold down position is not monitored. Always stroke out the hold down after changing pots, otherwise the pot may be damaged.

2 Regulator screw for pot pressure. 3 Pressure gauge. The pressure applied should be as low as possible to avoid shortening the block life. 4 Regulator screw for pot rotation. Depending on colour type, rotating the pot during the withdrawal may be beneficial. The rotation takes place as the pot moves back. 5 Adjusting screw for free running of the pot rotation. ( Do not change the factory setting ) 6 Pot hold down 7 Air connections for pneumatic hose 4 mm o.d.

1

3

2

Connection to pressure inspection

Position controller pot hold down (optional)

8 TPX 502-1 GB 23.10.2003

Image position on plate

Image position on plate Image pick-up

Image pick-up By sliding of the clamp (1) with pin spanner no. 4 and by turning of the adjusting knob, the printing pad is centered over the plate for the printing image pick-up.

1

9 23.10.2003 TPX 502-1 GB

Adjustment of the pad slide paths

Image intake adjustable range ± 43 mm Pad slide at back = B Image delivery adjustable range ± 27 mm Pad slide at front = A

1 revolution 2 mm

B A

B A

10 TPX 502-1 GB 23.10.2003

Insert ink disc in pot, the offset sliding surface points towards the block. The ink disc permits work with a minimum amount of ink. Place pot on block plate and press down slightly. Remove lock and fill with ink.

The pot hold-down can be moved up and down with the turning handle ( page 10 / 1 ) The pot cylinder can be moved with the rocker arm (on the left of the machine). Check the contact pressure on the pressure gauge. The pressure applied should be as low as possible to avoid shortening the block life.

Ink volume: Depending on pot size. Release plug during printing, so that no excess pressure is produced in the pot. Extend block slide and set pot holddown up. Insert block plate and push ink pot against machine until pot is centered under the pot cylinder. Set pot holddown down.

Filling with ink

11 23.10.2003 TPX 502-1 GB

Speed setting 1. Pad slide 2. Pad stroke

1 2

Speed setting

Important: The speed must not be increased after adjustment.

12 TPX 502-1 GB 23.10.2003

Ι3 (B33)

Ι4 (B34)

Incremental rotary transducer Monitoring of pad vertical stroke

Pneumatic system Valve block 1. Pad slide 2. Pad vertical stroke 3. Silencer

1

2 3

Proximity initiators The response gap between the proximity initiators and the actuators should be set at 0.5 mm

Ι1 Pad slide at rear

Ι2 Pad slide at front

Ι3 Ink pot at left

Ι4 Ink pot at right (over print image)

Maintenance instructions

Ι2 (B32)

Ι1 (B31)

13 23.10.2003 TPX 502-1 GB

Check on conditioning unit Cylinder with end-stop damping

Check on conditioning unit Oil feed regulator screw: Dose 5 drops per year. Oil: Hydraulic oil acc. to DIN 51 524 – HLP32 Oil viscosity: 32 cSt bei 40°C. Too much oil leads to overoiling (slow cylinder).

Working pressure shown on gauge Europa = 6 bar USA / GB = 87 psi 1 psi = 0,069 bar 1 bar = 14,5 psi

Screw-driver blade "0"

Cylinder with end-stop damping With very fine adjustment, excess oil may block end-stop damping. Check the end-stop

Adjusting screw

close open

- After oiling tighten adjusting screw in clockwise direction. ! Push in condensate drain

(Water) pin. Use intercepting tank.

14 TPX 502-1 GB 23.10.2003

Connections, LED (TPX 350 / 500) Output power 75 Watt

Output current (24 V =) : 3,2 A

Short-circuit proof LED green LED (green) → lights up, when the power unit is ready for operation. The LED goes out, when the power unit function is impaired. Possible causes are: - There is no primary voltage at the power unit input

- The secondary load is too high and the power unit cuts off

110 V Model TPX 350 / 500 The 110 V model includes a transformer for illumination. Conversion: Part No. 821 207 424 Wiring diagram power suplay : 706 700 019

24 V =

Gnd

85 - 265 V47 - 63 Hz

Power supply unit Art. no.: 821 207 414

15 23.10.2003 TPX 502-1 GB

+ -

Incoming supply I/O module

I17

I18

X5 PIN 7 X5 PIN 9

RUN

ERR

RUN

Gnd +24V

Connection for PC (RS 232)

18 17

I/O-Board

47 48

Connection to keyboard

Battery

Battery Kit Nano-T The service life of the battery is approx. 10 years. Please only have the battery changed by specialised staff. Item. No. 821 206 107 (incl. Installation instructions)

Connection for I/O-Modul

Nano-T control unit

16 TPX 502-1 GB 23.10.2003

Logic 5V (yellow) ERROR (red)

24 V Power supply (yellow)

From power supply

Emergency stopp switch (internal)

Incremental encoder

Encoder (LED yellow)

CAN-Bus out (female)

I/O-Modul

(signal contact) to external internal

CAN-Bus in (male)

from

Nan

o-T

24 V

u. G

nd

to N

ano-

T

emer

genc

y st

op

(ext

erna

l) soft

run-

up

(yel

low

) (r

ed)

Gnd

24

V

17 23.10.2003 TPX 502-1 GB

Exchanging the control unit Nano-T and the I/O module

Recessed head screw

Recessed head screw

Control unit Nano-T

I/O-Modul

1. Disconnect machine from power supply. 2. Remove control box casing. 3. Loosen plug-in connections and cables 4. Undo fastening screws

Important: When exchanging the control unit Nano-T please make sure that the same or latest software version is stored.

When exchanging, always state software version and ID number.

Software Version is on the rear side of the control box near the programming interface PC (RS232)

If the sign at the programming interface PC (RS232) is missing, see system information in the manual Nano-T page 36

18 TPX 502-1 GB 23.10.2003

Initiator locations

Ι3 (B33)

Ι4 (B34)

Switching gap initiator 0.5 mm

Ι1 (B31)

Ι2 (B32)

19 23.10.2003 TPX 502-1 GB

Incremental rotary transducer fitting

703 502 314 703 502 315 M5 x 25 M3 x 8 801 004 511 M4 x 10

I/O-Modul

A = blau, blue, bleu, azul, blu B = Schwarz, black, noire, negro, nero - = weiss, white, blanche, blanco, bianco + = braun, brown, brun, marron, bruno

703 502 023

703 502 314 703 502 315 M3 x 8 M5 x 25

20 TPX 502-1 GB 23.10.2003

Emergency stop

Emergency stop printing machine

Emergency stop button

Emergency stop extension

+24 V/ Gnd for control unit and inputs/outpus

Emergency stop valve

Control unit power supply to Nano-T + 24 V

Connections on PCB

Terminals I/O-modul see on page 16

21 23.10.2003 TPX 502-1 GB

Contact allocation X4 – X5, CAN-Bus, Foot switch

Stop tampon feed

Output impulse

(Start)

Output impulse

Stop tampon feed

Foot switch

Start

22 TPX 502-1 GB 23.10.2003

Connection for unlubricated air

Connection (M5) for clean unlubricated air

A

B

50

19.7

48120

48

TPX 350/TPX 500

H H

TPX350 / TPX 500Tamponbefestigung

706-535-003

21.01.02 WEMSTB. GEZEI.

GEPR. %

8240 THAYNGEN SWITZERLAND

TamponhalteschinePad mounting-railRail support du tampon

VerschiebesupportSlide supportSupport culissant

A B25 10 68 58 10025 20 68 58 9035 10 68 75 100

KlemmbrideDovetail adapter

Collier de serrage35 05 63

KlemmbrideDovetail adapter

Collier de serrage35 12 63

Tamponkonus mit Überwurf-mutter M16 x 1,5

Pad cone with sleeve nutCône pour support tampon avec écrou

35 01 61

Tamponhalter schmalPad holder small

Support-tampon étroit

35 50 63 H = 5035 60 63 H = 6035 70 63 H = 70

Tamponhalter zentrischPad holder centricalSupport-tampon centrique

35 25 62 H = 2535 30 62 H = 3035 40 62 H = 4035 50 62 H = 5035 60 62 H = 6035 70 62 H = 70

19.7

B

TPX 350 35 35 59TPX 500 704 502 320TPX 500/600 50 60 59

1.1

7.1

2.1 3.1 5.1 5.5

P

706 750 009

19.09.03 TA

ERSETZT DURCH

ERSATZ FUER

GEZEICHN.

GEPRUEFT

INDEX

8240 THAYNGEN SWITZERLAND

4.0

Topf

4.2 4.3

4.5

4.4

7.0

PneumatikschemaPneumatic-diagramDiagramme pneumatiqueDiagrama neumáticoDiagramma pneumatico

TPX 502TPX 502TPX 502TPX 502TPX 502

N

3.2 3.35.2 5.3

2.0 3.0 5.0

6.0

5.4

A

optional

2.32.2

5.0

5.4

3.0

3.2

5.2

1.1

2.1

3.1

5.1

5.5

3.3

5.3

706 750 010

19.09.03 TA

LageplanLayout diagramPlan de massePlano del conjuntoPlano di deposito

ERSETZT DURCH

ERSATZ FUER

GEZEICHN.

GEPRUEFT

INDEX

8240 THAYNGEN SWITZERLAND

TPX 502TPX 502TPX 502TPX 502TPX 502

4.0

2.0

6.0

A

2.32.2

I 101/I 102

Sanftanlaufventilsoft-start valve

17/18

oder Brücke (Klemme 1+3)or bridge (terminal 1+3)

interne Ausgängeinternal outputs

interner Notausinternal emergency stop

NetzteilPower supply unit

AC

24V DC 24V DC

I/ O -Modul

RS-422 (1:1)

Display und TastaturDisplay and keyboard

24V DC

24V DC

Inkremental- drehgeberEncoder

CAN-Bus in

CAN-Bus out

15-pol.

NANO-T

Netzeinganginput power supply

optional (5 pol. Preh Buchse)optional (5 pol. Preh female)

X5FussschalterFoot swich

X4

X4

NotauserweiterungEmergency stop extension

SteuerungsrückwandPLC back plate

optional mit Kabelaustauschoptional by changing cable

9-pol.

Maschinenrückwandmachine back plate

RS 485 (Jetway) 15 pol. Sub-D BuchseRS 485 (Jetway) 15 pol. Sub-D female

CAN-Bus und 24V zu externer Peripherie mit I/O16-Modul 15 pol. Sub-D BuchseCAN-Bus and 24V to external peripherie with I/O16-Modul 15 pol. Sub-D female

RS 232 9 pol. Sub-D BuchseRS 232 9 pol. Sub-D female

706 700 018

23.04.02 WE

Steuerungskomponenten und SchnittstellenControl components and interface

ERSETZT DURCH

ERSATZ FUER

GEZEICHN.

GEPRUEFT

INDEX

8240 THAYNGEN SWITZERLAND

Technische Aenderungen vorbehaltenWe reserve the right to make any technical changesSous reserve de modifications techniquesReservato el derecho de realizar modificaciones tecnicasCon riserva di mutazioni techniche

NANO-T

oder Brücke (Klemme 11+12)or bridge (terminal 11+12)

interne Eingängeinternal inputs

O2 I11

Inkremental- drehgeberEncoder

39

34

I1

I2

I3

I4

31

32

33

I5

I6

I7

I8

I9

35

36

37

38

I11

I12

I13

I14

I1040

I17

I18

I15

I16

O1

47

48

51

I13

3

1

4

2

13

11

9

5

7

6

8

12

14

10

REL C

X51

14

3

2

15

GndI10

REL NOO9

8

5

4

6

17

16

18

19

7

20

REL NCI11O15I15I7I8I12

I14I17

23

21

19

17

15

24

22

20

18

16

25

3

1

4

2

26+24V

13

9

11

10

21

22

23

24

12

25

I9I18I6I16O10O11O12O13O14

X4

2

1

6

3

7

REL NOGnd

REL CREL NC

O12

O7

O3

O4

O5

O6

52

53

54

55

56

O10

O11

O8

O9

57

58

59

12A2

24V für Ausgänge und Logik24V for outputs and logic

O15

O16

O13

O14

GND

BA

Kanalchannel

A1

+ -

2

3

1

21

22

5

4

11

12

CAN-BUS

9

5

7

10

6

8

14

3

2

1

FS4

REL NO

X4

4

5

9

8

1

6

+24V

O15I12O11

Gnd

4

2

7

3

8

5

9

REL NCREL C

I11O15

+24V

I12O11

Belegung des CAN-Bus-SteckersPin 1-9 nach Jetter-Standard11

24V u. Gndan NANO-Tto NANO-T

-

24

-

++

-

von Netzteilfrom power supply unit

+24V

Gnd

13

1

2

3

4

5

9

10

11

12

Gnd

Gnd

Gnd

6

7

8

14

15

+24V

+24V

+24V

706

700

02023

.04.

02

WE

Ver

drah

tung

X4/

X5

- I/O

-Mod

ulW

iring

X4/

X5

- I/O

-Mod

ul

ER

SE

TZ

T D

UR

CH

ER

SA

TZ

FU

ER

GE

ZE

ICH

N.

GE

PR

UE

FT

IND

EX

8240 T

HA

YN

GE

N S

WIT

ZE

RLA

ND

Tech

nisc

he A

ende

rung

en v

orbe

halte

nW

e re

serv

e th

e rig

ht to

mak

e an

y te

chni

cal c

hang

esS

ous

rese

rve

de m

odifi

catio

ns te

chni

ques

Res

erva

to e

l der

echo

de

real

izar

mod

ifica

cion

es te

cnic

asC

on r

iser

va d

i mut

azio

ni te

chni

che

NA

NO

-T

connection of CAN-Bus-plugPin 1-9 like Jetter-Standard

Sanftan- lauf- ventilSoft start valve

Notaus- SchalterEmergency stop button

Notaus- Erwei- terungEmergency stop extension

12

230V

/50H

z

L1

S1.

0

PEN

58265 0002

L1.3

821 209 671

S1.

3

821 207 424

3

optional 110 V

423

0V

110V

nur / only TPX350/500

24V

230V

N

FG

-

L+

820

207

413

/ 820

207

414

I/O-moduleOV

703 008 102

24 V

706 700 019

24.03.03 WE

SpannungsversorgungPower suplay

ERSETZT DURCH

ERSATZ FUER

GEZEICHN.

GEPRUEFT

INDEX

8240 THAYNGEN SWITZERLAND

Technische Aenderungen vorbehaltenWe reserve the right to make any technical changesSous reserve de modifications techniquesReservato el derecho de realizar modificaciones tecnicasCon riserva di mutazioni techniche

NANO-T

B

29 23.10.2003 TPX 502-1 GB

Inputs used internally I1 (E201) Pad slide rear I2 (E202) Pad slide forward I3 (E203) Ink pot left I4 (E204) Ink pot right (over print image) I5 (E205) Raise cutter / pressure switch by pot machine Inputs for use internally and/or on X5 I6 (E206) Pin 22 Safety door switch / TFC indexing down I7 (E207) Pin 18 TFC single step I8 (E208) Pin 6 TFC On-Off I9 (E301) Pin 21 TFC indexing up TPX 500 L: Cleaning position Inputs used internally and on X5 I10 (E302) Pin 14 Machine start Inputs used on X5 I11 (E303) Pin 4 Stop continuous running / no fault cleaning tape (only in PLC mode) I12 (E304) Pin 19 Stop pad stroke Inputs for use on X5 only I13 (E305) Pin 8 Pad cleaning forward I14 (E306) Pin 20 Pad cleaning rear I15 (E307) Pin 5 PLC stop TP-slide back / RT advance rear / VTP in position / Set-up TFC I16 (E308) Pin 10 TFC advance forward I17 (E101) Pin 7 ext. start TAC / Ejector rear I18 (E102) Pin 9 Unlock TFC

Assignment of inputs of NANO-T control unit

30 TPX 502-1 GB 23.10.2003

Outputs used internally O1 (A201) Pad slide O2 (A202) Ink pot right O3 (A203) Pad stroke O4 (A204) Cutter O5 (A205) Slow motion Outputs for internal use O6 (A206) Pad cleaning O7 (A207) Ink pot left O8 (A208) Height equalization Outputs for use internally and/ or on X5 O9 (A301) Pin 2 Ejector Latch if TPX 460 K TPX 500 L: Cleaning position Outputs for use on X5 only O10 (A302) Pin 23 PLC Busy / RT advance / VTP to right O11 (A303) Pin 11 PLC pad slide in motion / VTP to left O12 (A304) Pin 24 Unlock VTP latch O13 (A305) Pin 12 TFC indexing high O14 (A306) Pin 25 TFC advance Outputs used on X5 O15 (A307) Pin 17 Output pulse (signal) / clock TFC O16 (A308) Relay Pin 3 C/ Pin 15 NO/ Pin 16 NC (cleaning motor)

Assignment of outputs of NANO-T control unit

31 23.10.2003 TPX 502-1 GB

Fault Cause Remedy

Holes in print

• Air bubbles on ink pick-up. • Ink is too thin. • Pad is too flat. • Pad down-stroke too fast; hence too high a

roll-over speed of pad print surface.

• Adjust for thicker ink. • Take steeper pad. • Reduce speed of pad down-stroke.

Splashes

• If the pad is splashed, this happens when the

pad retracts from the plate. Reason: • Some of the deformation energy is

converted to a static charging of the pad and the ink.

• Check the pad after ink take-up (mirror). • Adjust for thinner ink. • Use a softer pad. • Fit an ionizing rod in front of the plate.

Clouds

• Occurs frequently in wide-area print zones

(pad float), especially when printing non-flat surfaces; e.g. cylinders, cones.

• Fill the low points, expand the pad roll

surface. • Special measures are necessary.

Distortion

• Print surface has low points or high points, or

is smaller than the pad area. • Print on non-plane surface is always

distorted.

• Fill the low points, expand the pad roll

surface. • Special measures are necessary.

Too little ink = insufficient opacity

• Ink too thick (viscosity). • Pad not yet activated. • Inadequate plate depth, or ink clotted. • Machine cycle time is too long or too

irregular. • Pad retains too much ink.

• Thin the ink. • Activate pad with thinner. • Check the plate and clean if necessary. • Reduce machine cycle time. Work with

automatic control. Check work bench layout. • Blow cold air on pad, or prolong time

between ink take-up and deposit. (Do not use retarder).

Ink distribution non-uniform

• Plate or film do not sound. Depth of etch irregular. • Plate part-clogged with ink. • Ink is crushed by the pad. • Pad stroke too short.. • Ink is too thick. (Saturation fault). • Too little ink.

• Check the film. • Clean the plate. • Set for thicker ink. • Correct pad stroke. • Check saturation. • Top up with ink; mix well.

Contours not clear-cut

• Ink is too thin. Ink is crushed. • Cycle time is too long or too irregular. • Pad stroke too short. • Retarder used. • Possibily too great an etching depth > 30 microns.

• Set for thicker ink. • Keep to cycle time. • Correct pad stroke. • Work without retarder. • New plate. Etching depth for steel plate:

Normal 22 microns, for fine marks 16 microns.

• Use plastic screen film E 7812.

Possible printing faults The pad can only yield as good a pattern as it has picked up. If faults occur, make the following checks first:

• Is the plate saturated with ink? • Check the ink pick-up on the pad (with mirror).